Arc welding system



Nov. 6, 1951 D. c. GIRARD ErAL ARC WELDING SYSTEM Original Filed Dec. 29. 1948 Patented Nov. 6, 1951 ABC WELDING SYSTEM DeanC.Girard,BanLeandro,and!rankT. Roach, Hayward, Calif., anignon, by meme as. aigmnents, to National Cylinder Gas Company,

a corporation of Delaware continuum of application serial No. um, n-

umn 1,

climber 29, 1948.

1950, Serial No. 148,182

l 12 Claims.

This invention relates, generally, to arc welding systems, and it has particular relation to gas shielded arc welding in which the arc is stabilized by superimposed high frequency. This application is a continuation of application Serial No. 67,795, filed December 29, 1948, now abandoned.

Among the objects of this invention are: To generate the high frequency arc stabilizing current only while the welding operation is being performed; to initiate the operation of the high frequency generator by short circuiting the weiding circuit on a relatively low voltage source; and to maintain the flow of welding current only while the high frequency arc stabilizing current is being generated.

Other objects of this invention will, in part, be obvious and in partappear hereinafter.

This invention is disclosed in the embodiment thereof shown in the accompanying drawing, and it comprises the features of construction, combination of elements, circuit connections, and arrangement of parts which will be exemplified in the description hereinafter set forth and the scope of the application of which will be indicated in the appended claims.

For a more complete understanding of the nature and scope of this invention, reference may be had to the following detailed description, taken together with the accompanying drawing in which the single figure illustrates diagrammatically the circuit connections which may be employed in practicing this invention.

Referring now particularly to the drawing, it will be observed that the reference character I designates a source of alternating current, such as a 220 volt 60 cycle source. It will be understood that other voltages and frequencies can be employed, the particular values specified being for illustrative purposes only. The source I0 may -be connected by line switches II and a line contactor, shown generally at I2, to energize aprimary winding I3 of a welding transformer that is shown, generally, at I4. The welding transformer I4 includes a secondary winding I5 whose open circuit voltage may be of the order of eighty 'to ninety volts. The line contactor I2 includes an operating winding I2w, normally closed contacts |2a whose function will be described hereinafter, and normally open contacts I2b and I2c. It will be observed that the contacts I2b, when closed, serve to connect the primary winding I3 for energization to the source I0 when the switches II are closed. Contacts I2c are provided to connect a capacitor I8 across the primary winding I3 for power factor correction.

This application The secondary winding il of the welding transformer Il may be connected by conductors I1 and Il to supply current for maintaining a welding arc Il between an electrode 2l, which may be of the non-consumable type, and work 2l on which the welding operation is to be performed. An inert gas, such as argon, may be supplied through a conduit 22 around the electrode 2l and the arc I9 in accordance with conventional shielded arc welding practice.

Since the welding arc II is supplied from the secondary winding Il of the welding transformer I4 with relatively low frequency alternating current, diiiiculty is encountered in striking and maintaining the arc. The tungsten electrode 20 should not touch the work 2| except to a very minor extent for it will be contaminated and interfere with proper operation. In order to assist in striking and maintaining the arc, provision is made for superimposing on it a current oi a relatively high frequency. For this purpose frequencies in the band from 27.16 to 27.48 megacycles have been set aside tentatively. A frenuency of 27.32 megacycles has been chosen from this permissible -band of frequencies for stabilizine the operation of the arc I 9.

The stabilizing high frequency is Supplied to the arc I9 in close proximity thereto. For this purpose an inductor 23 is connected between the welding electrode 20 and the conductor I1, as shown. The inductor 23 has terminals 23 and 25. It will be noted that the terminal 24 is immediately adjacent the electrode 20 while the terminal 25 provides for connection to the welding lead or conductor I 1.

The stabilizing high frequency is applied across the inductor 23 by means of a co-axial cable that is shown, generally, at 26. It will be noted that the inner conductor 21 of the co-axial cable 2l is connected to the terminal 24 of the inductor 23 which is adjacent the electrode 20 and the arc I9. The outer conductor 28 of the co-axial cable 26 is connected to the other terminal 25 of the inductor 23. It will be understood that the length of the co-axial cable 26 is chosen with respect to the wave length of the stabilizing frequency employed so that the high frequency current is transmitted therethrough with a minimum of loss and a maximum of eiciency. overheating of the co-axial cable 23 is avoided. At the same time sufficient power is available across the inductor 23 to provide the desired stabilizing effect on the arc I9.

The conductors 21 and 28 which comprise the co-axial cable 26 may be connected through inductor 35 has a center tap. as shown, which is connected through a radio frequency choke coil 31 to ground at 33.

The generator 36 includes a double triode electric valve 39 which is of known design and con struction. 'Iype 304TL has been found satisfactory for the purposes of the generator 36. It will be understood, however, that two separate single triode valves can be employed, if desired, in lieu of the double triode electric valve 39 illustrated.

The valve 39 includes an anode or plate 40 and a control grid 4I, these being connected, as shown, to the ends of the inductor 35. The valve 39 also includes a pair of hot cathodes 42 which may be heated by secondary windings 43 of a iilament transformer, shown generally. at dd, which has a primary winding 45.

Any suitable means can be provided for energizing the primary winding 45. As shown, a switch 46 is employed for connecting the primary winding 45 for energization across a secondary winding 41, operating at 110 volts, which forms a part of a transformer, shownV generally at 48. The transformer 43 has a primary winding B9 which may be connected for energization across the source I Il when the switches II are closed. In addition the transformer 49 has a low voltage secondary' winding 53 arranged, as indicated, to operate at about seven volts, and used for a purpose to be described presently.

Capacitors 53 serve to interconnect the hot cathodes 42 and their mid point is connected to ground at 54 in accordance with conventional practice.

As indicated, the generator 36 is of the selfrectifying type. In order to accomplish this radio frequency choke coils 55 interconnect the circuits to the hot cathodes 42 with a secondary winding 56 of-a plate transformer that is indicated, generally, at 51. A primary winding 58 forms another part of the transformer 51 and it is arranged to be connected in a manner to be described presently for energization across the secondary winding 41 of the transformer 46. It is desirable that the high frequency generator 36 function only during the time that the arc I9 is maintained between the electrode 23 and the work 2|. radio interference since there is none when the generator 36 is not functioning and emission is at a minimum when the arc I9 is being maintained. In order to initiate the generator 36 in operation when it is desired to strike the arc I9 a start relay, shown generally at 59, is provided. The start relay 59 includes an operating winding 59m, normally open contacts 59a and normally closed contacts 59h.

A response to the operation of the high frequency generator 36 may be provided by a high frequency generator relay that is shown, generally, at 60. The relay 60 has an operating winding 6Ilw and normally open contacts 63a and 63h. As shown, the operating winding 6|Iw is connected between a mid point of the secondary winding 56 and ground 6I.

In describing the functioning of the system shown in the drawing, it will be assumed that incrt gas is being supplied through the conduit 22 This reduces the likelihood of that the switches II and 49 have been closed and that the line contactor I2 and. relays 59 and d@ are in the deenergized or dropped positions shown in the drawing. The impedance oi secondary winding I5 is high enough to prevent energize tion of the winding 59w therethrough. The op erator momentarily touches the electrode 2@ on the work 3 I.

As soon as the electrode acengages the work 2E a circuit is completed for energizing the operating winding 59w of the start relay 69. This circuit may be traced from the low voltage secondary winding of the transformer 49, through conductor 62, operating winding 59w, conductor 63, conductor I8, work 2i, electrode 2B, inductor 23, conductor I1, conductor 64, normally closed contacts I2a and conductor 65 to the other side of the low voltage secondary winding Bil. It will be apparent that the operator has to contend here with only a relatively low voltage, for example a voltage of the order of seven volts, which, as far as he is concerned, is entirely harmless.

As soon as the operating winding 59w of the start relay 59 is energized in the manner` just described, the circuit to the operating winding I2w of the line contactor I2 is opened at contacts 59h and at contacts 59a a circuit is completed for energizing the primary winding 53 of the plate transformer 51. This circuit may be traced from one terminal of the secondary winding d1 of the transformer 48 through conductors 66 and 91, primary winding 58, conductor 68, contacts 59a and conductors 69 and 19 to the other side of the secondary winding 41. Plate potential now is applied to the valve 39 and suilcient current ows through the operating winding u: of the generator relay 60 to close its contacts Sila and 60h.

Nothing further happens until the operator withdraws the electrode 20 from the work 2l while maintaining it close thereto so that the arc I9 now provided solely by the high frequency current will continue. However, the previously traced circuit for energizing the operating winding 59w of the start relay 59 is opened and this relay drops. Although contacts 59a are opened by the dropping of start relay 59, the circuit for energizing the primary winding 58 of the plate transformer 51 is maintained through contactsr 69a of the generator relay 63. It will be observed that the contacts 59a are connected in parallel with the contacts 60a. by conductors 66 and 13.

The dropping of the start relay 59 completes a circuit at 59h for energizing the operating winding I2w of the line contactor I2. This circuit may be traced from one side of the secondary winding 41 of the transformer 43 through conductor 66, contacts Elib, conductor 1d, contacts 59h, conductor 15, operating winding i214:

and conductor 10 to the other side of the second l ary winding 61.

The line contactor I2 now picks up and at contacts I2b and I2c closes the circuits for energizing the primary winding I3 of the welding transformer I4 and connecting the capacitor IB thereacross. Welding current now is induced in the secondary winding I5 of the welding transformer Il and it flows through the conductors or weld- Ing leads I1 and I8 and the Inductor 23 to provide the required current for the arc I9 which now is being stabilized by the superimposed high frequency from the generator 36.

Since contacts I2a are opened when the line contactor Il vis in the operated position, no current can flow through the operating winding "w of the start relay Il. It will be noted that the winding elw of the generator relay Il is connected by a conductor 16 to the mid point of the secondary winding It and by a conductor l1 to ground Il.

The welding operation ceases when the operator moves the electrode 20 sumciently far from the work 2l so that the arc cannot be sustained. This action then unloads the generator 3l to a sumcient extent so that the current flow through the plate circuit is reduced and, as a result, winding Gliw of the generator relay 60 is deenergized suillciently to permit its contacts 60a and 30h to be opened. The previously traced circuit for energizing the primary winding 58 of the plate transformer 51 through contacts 60a is opened and it is deenergized. At contacts 60h the energizing circuit for the operating winding I2w of the iine contactar I2 is opened and it drops. The ssytexn now is restored to the initially assumed position and, on resumption of welding operations, the cycle just described is repeated.

Since certain changes can be made in the foregoing construction and different embodiments of the invention can be made without departing from the spirit and scope thereof, it is intended that all matter shown in the accompanying drawing and described hereinbefore shall be interpreted as illustrative and not in a limiting sense.

What is claimed as new is:

i. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination, a line contacter for connecting the power circuit for energization to a current source, a start relay, circuit means connecting said start relay to be energized on application of predetermined load to said power circuit when said line contactor is open, a high frequency generator connected to superimpose high frequency on said power circuit and to be initiated in operation by closing oi said start relay, a generator relay, and circuit means connecting said generator relay to be energized on operation of said generator, said generator relay being arranged to maintain the said generator in operation and to efect the closure of said line contactor after said start relay drops.

2. The invention, as set forth in claim l, wherein the high frequency generator is of the electric valve type and the generator relay is responsive to flow of unidirectional current therethrough.

3. The invention, as set forth in claim 1, wherein the voltage of the current source for energizing the start relay is substantially lower than the normal open circuit voltage of the load circuit.

4. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination; a line contactor having an operating Winding, normally open contacts for connecting said power circuit to a current source, and normally closed contacts; a start relay having an operating winding connected in series with said power circuit through said normally closed contacter contacts to a current source and energized on application of predetermined load to said power circuit, a set of normally closed contacts, and a set of normally open contacts; a high frequency generator connected to superlmpose high frequency on said power circuit;v a generator relay having a winding responsive to the operation of said generator and two sets of normally open contacts; circuit means connected through said normally open contacts of saidstart relay on closure thereof to initiate the operation of said generator and thereby eifeot the energization o! said generator relay winding and closure of its contacts, circuit means connecting one set of generator relay contacts in parallel with said normally open start relay contacts to maintain said generator in operation when said start relay drops. and circuit means connecting said contactor winding for energization to a current source through said normally closed start relay contacts and the other set of generator relay contacts whereby on removal of the load from said power circuit said start relay drops and said normally open line contacter contacts are closed.

5. The invention, as set forth in claim 4. wherein the high frequency generator is of the self rectifying self-excited electric valve type and the generator relay is responsive to ilow of unidirectional current therethrough.

6. The invention, as set forth in claim 4. wherein the voltage of the current source for energizing the start relay winding is substantially lower than the normal open circuit voltage of the load circuit.

7. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination, a line contactor for connecting the power circuit for energization to a current source and having normally closed contacts, a first relay, circuit means connecting said first relay to be energized through said normally closed contacts on application of predetermined load to said power circuit, said first relay having normally closed and normally open contacts, a second relay, and circuit means connecting said second relay to be energized as a result of the closure of said normally open contacts of said first relay on energization thereof, said second relay having two sets of normally open contacts. one of said two sets of normally open contacts being connected in parallel with said normally open contacts of said iirst relay 'for maintaining said second relay energized and the other of said two sets of normally open contacts being connected in series with said normally closed contacts of said first relay for energizing said line contacter on removal of said predetermined load from said power circuit.

8. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination, a line contactor for connecting the power circuit for energization to a current source. a tlrst relay, circuit means connecting said first relay to be energized on application of predetermined load to said power circuit when said line contacter is open, a second relay, and circuit means connecting said second relay to be energized as a result of the energization of said ilrst relay and arranged on removal vof said predetermined load from said power circuit and deenergization of said first relay to energize said line contacter.

9. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination, a line contactor for connecting the power circuit for energization to a current source, a rst relay, circuit means connecting said first relay to be energized in series with said power circuit on application of predetermined load thereto when said line contacter is open, a second relay, and circuit means connecting said second relay to be energized as a result of the energization of said rst relay and 7 arranged on removal o! said predetermined load from said power circuit and deenergization oi' said rst relay to energize said line contactor.

10. A system i'or controlling the energization7 of an intermittently loaded power circuit comprising, in combination, a line contacter for connecting the power circuit for energization to a current source. a nrst relay. circuit means connecting said rst relay to be energized from a separate current source on application of predetermined load to said power circuit when said line contactor is open, a second relay, and circuit means connecting said second relay to be energized as a result of energizatlon of said ilrst relay and arranged on removal o! said predetermined load from said power circuit and deenergization of said tirst relay to energize said line contacter.

11. A system for controlling the energization oi' an intermittently loadedl power circuit comprising, in combination, a transformer having a primary winding for energization from a source o! alternating current anda secondary winding for connection to said power circuit, a line contactor for connecting said primary windingfor energization to said source of alternating current, a iirst relay. circuit means connecting said irst relay to be energized in series with said power circuit when it is short circuited and said line contactor is open. a second relay. and circuit means connecting said second relay to be energized as a result o! the energization of said iirst relay and arranged on removal of the short circuit and deenergization of said iirst relay to energize said line contacter.

12. A system for controlling the energization of an intermittently loaded power circuit comprising, in combination.. a transformer having a primary winding for energization from a source of alternating current and a secondary winding for connection to said power circuit, a line contactor for connecting said primary winding for energization to said source of alternating current. a rst relay, circuit means connecting said :first relay to be energized from a separate current source in series with said power circuit when it is short clrcuited and said line contacter is open, a second relay, and circuit means connecting said second relay to be energized as a result oi' the energization of said first relay and arranged on removal' o the short circuit and deenergization of said first relay to energize said line contacter.

DEAN C. GIRARD. @RANK T. ROACH.

No references cited. 

